Method of making ceramic shaped abrasive particles, sol-gel composition, and ceramic shaped abrasive particles

ABSTRACT

A method includes: providing a mold having a plurality of mold cavities, wherein each mold cavity is bounded by a plurality of faces joined along common edges; filling at least some of the mold cavities with a sol-gel composition that includes a release agent dispersed therein; at least partially drying the sol-gel composition thereby forming shaped ceramic precursor particles; calcining at least a portion of the shaped ceramic precursor particles to provide calcined shaped ceramic precursor particles; and sintering at least a portion of the calcined shaped ceramic precursor particles to provide ceramic shaped abrasive particles. A sol-gel composition, shaped ceramic precursor particles, and ceramic shaped abrasive particles associated with practice of the method are also disclosed.

FIELD

The present disclosure broadly relates to abrasive particles and methodsof making them.

BACKGROUND

According to a known method of making ceramic shaped abrasive particles,a sol-gel composition comprising a ceramic precursor material is urgedinto mold cavities in a mold. The mold cavities typically have apredetermined shape; for example, corresponding to a regular geometricshape such as a pyramid or truncated pyramid. The sol-gel composition isthen partially dried, and the resulting shaped ceramic precursorparticles are removed from the mold and further processed into ceramicshaped abrasive particles.

SUMMARY

During removal of the shaped ceramic precursor particles from the moldcavities the partially dried sol-gel composition is relatively fragileand may be prone to sticking, thereby leading to breakage and/orclogging of the mold cavities in the mold. To overcome this problem,release agents have been applied to the mold prior to filling the moldcavities. However, the application of release agents to the mold maylead to shape changes of the sol-gel composition before and/or duringdrying such that the resulting shapes may not correspond to the shape ofthe mold cavities. This phenomenon causes problems with reproducibilityduring production such as controlling flatness and/or aspect ratio ofthe partially dried sol-gel material, and hence the resulting ceramicshaped abrasive particle. Additionally, the application of releaseagents to the mold may not be reliably coat the mold cavities in caseswherein they are very small.

Advantageously, the present inventors have discovered that theaforementioned problems can be overcome by including small amounts ofdispersed oil in the sol-gel composition, while still obtainingdesirable abrasive properties such as, for example, high density (lowporosity).

In one aspect, the present disclosure provides a method of making shapedceramic precursor particles, the method comprising:

providing a mold having a plurality of mold cavities, wherein each moldcavity is bounded by a plurality of faces joined along common edges;

filling at least some of the mold cavities with a sol-gel composition,the sol-gel composition comprising a liquid vehicle and a ceramicprecursor, the liquid vehicle comprising a volatile component and arelease agent dispersed throughout the volatile component;

removing at least a portion of the volatile component from the sol-gelcomposition while the sol-gel composition resides in the mold cavitiesthereby providing the shaped ceramic precursor particles.

In another aspect, the present disclosure provides a method of makingceramic shaped abrasive particles, the method comprising:

making shaped ceramic precursor particles according to a method of thepresent disclosure; and

sintering at least a portion of the shaped ceramic precursor particlesto provide the ceramic shaped abrasive particles.

In another aspect, the present disclosure provides a method of makingceramic shaped abrasive particles, the method comprising:

making shaped ceramic precursor particles according to a method of thepresent disclosure;

calcining at least a portion of the shaped ceramic precursor particlesof claim 1 to provide calcined shaped ceramic precursor particles; and

sintering at least a portion of the calcined shaped ceramic precursorparticles to provide the ceramic shaped abrasive particles.

In another aspect, the present disclosure provides a sol-gel compositioncomprising a liquid vehicle and a ceramic precursor, the liquid vehiclecomprising a volatile component and a release agent dispersed throughoutthe volatile component, wherein the sol-gel composition comprises asol-gel.

In another aspect, the present disclosure provides shaped ceramicprecursor particles, wherein each shaped ceramic precursor particlecomprises a ceramic precursor and is bounded by a surface having aplurality of faces joined along common edges, wherein the surface hasvoids on at least a portion thereof, wherein the voids are shaped ashollow ellipsoidal sections, wherein the plurality of faces comprises:

-   -   an exposed face having a portion of the voids thereon, wherein        the exposed face has a first density of the voids; and    -   a mold face that is smaller in area than the exposed face,        wherein the mold face has a portion of the voids thereon,        wherein the mold face has a second density of the voids, and        wherein the first density of the voids is greater than the        second density of the voids.

In another aspect, the present disclosure provides shaped ceramicprecursor particles, wherein each shaped ceramic precursor particlecomprises a ceramic precursor and is bounded by a surface having aplurality of faces joined along common edges, wherein the surface hasvoids on at least a portion thereof, wherein the voids are shaped ashollow ellipsoidal sections, wherein the plurality of faces comprises:

-   -   an exposed face having a portion of the voids thereon, wherein        the exposed face has a first density of the voids; and    -   a mold face, wherein the mold face has a portion of the voids        thereon, wherein the mold face has a second density of the        voids, and wherein the first density of the voids is greater        than the second density of the voids.

In another aspect, the present disclosure provides ceramic shapedabrasive particles, wherein each ceramic shaped abrasive particlecomprises a ceramic material and is bounded by a surface having aplurality of faces joined along common edges, wherein the surface hasvoids on at least a portion thereof, wherein the voids are shaped ashollow ellipsoidal sections, wherein the plurality of faces comprises:

-   -   an exposed face having a portion of the voids thereon, wherein        the exposed face has a first density of the voids; and    -   a mold face that is smaller in area than the exposed face,        wherein the mold face has a portion of the voids thereon,        wherein the mold face has a second density of the voids, and        wherein the first density of the voids is greater than the        second density of the voids.

In another aspect, the present disclosure provides ceramic shapedabrasive particles, wherein each ceramic shaped abrasive particlecomprises a ceramic material and is bounded by a surface having aplurality of faces joined along common edges, wherein the surface hasvoids on at least a portion thereof, wherein the voids are shaped ashollow ellipsoidal sections, wherein the plurality of faces comprises:

-   -   an exposed face having a portion of the voids thereon, wherein        the exposed face has a first density of the voids; and    -   a mold face, wherein the mold face has a portion of the voids        thereon, wherein the mold face has a second density of the        voids, and wherein the first density of the voids is greater        than the second density of the voids.

The ceramic shaped abrasive particles may be wholly composed of aceramic material such as, for example, alpha alumina, and may havesubstantially a uniform morphology throughout the ceramic shapedabrasive particles.

As used herein:

The term “ellipsoid” includes ellipsoids and spheres, wherein a sphereis considered to be a special case of an ellipsoid.

The term “ellipsoidal section” refers to a section of an ellipsoidobtained by bisecting the ellipsoid with a plane.

The term “shaped ceramic precursor particle” means an uncalcined,unsintered particle produced by removing a sufficient amount of theliquid vehicle from the sol-gel composition, when it is in a moldcavity, to form a solidified body that can be removed from the moldcavity and substantially retain its molded shape in subsequentprocessing operations.

The term “ceramic shaped abrasive particle”, means a ceramic abrasiveparticle with at least a portion of the abrasive particle having apredetermined shape that is replicated from a mold cavity used to form ashaped ceramic precursor particle. The shaped ceramic precursor particlewill generally have a predetermined shape that substantially replicatesthe mold cavity that was used to form the ceramic shaped abrasiveparticle. Ceramic shaped abrasive particle, as used herein, excludesabrasive particles obtained by a mechanical crushing operation.

The term “theoretical oxide weight” as applied to a ceramic precursorrefers the corresponding weight of ceramic produced by the ceramicprecursor after sintering to form the ceramic (e.g., aluminum oxidemonohydrate transforming to alpha alumina)

When referring to molded particles, the term “face” means a surfacehaving a predetermined shape that is substantially replicated from amold cavity. A face may correspond to a mold cavity wall (i.e., a moldface) or the opening of the mold cavity (i.e., an exposed face).

Features and advantages of the present disclosure will be furtherunderstood upon consideration of the detailed description as well as theappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic process flow diagram showing an exemplary methodof making ceramic shaped abrasive particles according to the presentdisclosure.

FIGS. 2A and 2B are, respectively, top and bottom schematic perspectiveviews of exemplary shaped ceramic precursor particles according to thepresent disclosure.

FIGS. 3A and 3B are, respectively, top and bottom schematic perspectiveviews of exemplary ceramic shaped abrasive particles according to thepresent disclosure.

FIGS. 4A and 4B are photomicrographs of ceramic shaped abrasiveparticles prepared in Example 12.

While the above-identified drawing figures set forth several embodimentsof the present disclosure, other embodiments are also contemplated; forexample, as noted in the discussion. In all cases, the disclosure ispresented by way of representation and not limitation. The figures maynot be drawn to scale. Like reference numbers may have been usedthroughout the figures to denote like parts.

DETAILED DESCRIPTION

An exemplary method of making ceramic shaped abrasive particles is shownin FIG. 1. In a first step, a mold is provided having a plurality ofmold cavities. Each mold cavity is bounded by a plurality of sidesjoined along common edges and at least one outer opening. The mold canhave a generally planar bottom surface and an opposite top surface. Thetop surface may be a structured surface that defines the mold cavities.The mold can be, for example, a belt, a sheet, a continuous web, acoating roll such as a rotogravure roll, a sleeve mounted on a coatingroll, or die. The mold cavities can be configured such that sol-gelcomposition contained within the mold cavities will have at least oneface exposed to air (or other gas) during drying.

In some embodiments, the mold has mold cavities with an outer openingbounded by one or more sides, and optionally a bottom face. The side(s)and optional bottom face may be planar or curviplanar, and are joined toone another along common edges (i.e., edges joining two faces). Sol-gelcomposition in such mold cavities has at least one (e.g., one or two)exposed face during initial drying of the sol-gel composition. Exemplarymolds of this type are described in U.S. Patent Appln. Publ. No.2010/0146867 A1 (Boden et al.). The bottom face may be designed into aunitary mold, or it may be formed from the second part of a two-partmold, for example, as described in U.S. Pat. No. 5,201,916 (Berg etal.).

In some embodiments, the mold cavities correspond to openings with oneor more sides and no bottom surface (e.g., opening formed through asheet as described in U.S. Pat. No. 5,201,916 (Berg et al.). The sidesmay be planar or curviplanar and adjacent sides are joined to oneanother along common edges. Sol-gel composition in such mold cavitieswill have two exposed faces during initial drying if not removed fromthe mold cavities. In some embodiments, sol-gel-compositions in such amold may be separated from the mold and disposed on substrate prior toinitial drying. In such embodiments, on that portion of the sol-gelcomposition that is in contact with the substrate is not an exposed toair (or other gas) during drying.

The mold can comprise any suitable material such as, for example, metal,or a polymeric material. Examples of suitable polymeric materialsinclude thermoplastics such as polyesters, polycarbonates, poly(ethersulfone), poly(methyl methacrylate), polyurethanes, polyvinylchloride,polyolefins, polystyrene, polypropylene, polyethylene or combinationsthereof, and crosslinked thermosetting materials. In some embodiments,the entire mold is made from a polymeric material. In anotherembodiment, the top surface of the mold, which includes the moldcavities, and which is in contact with the sol-gel composition whiledrying, comprises polymeric materials and other portions of the moldingcan be made from other materials. For example, a suitable polymericcoating may be applied to a metal mold to change its surface tensionproperties.

A polymeric mold can be replicated off a metal master tool. The mastertool will have the inverse pattern desired for the mold. The master toolcan be made in the same manner as the mold. In some embodiments, themaster tool is made out of metal (e.g., nickel) and is diamond turned. Apolymeric sheet material can be heated along with the master tool suchthat the polymeric material is embossed with the master tool pattern bypressing the two together. A polymeric material can also be extruded orcast onto the master tool and then pressed. The polymeric material iscooled to solidify and produce the mold. If a thermoplastic mold isutilized, then care should be taken not to generate excessive heat thatmay distort the thermoplastic mold limiting its life. More informationconcerning the design and fabrication of molds and/or master tools canbe found, for example, in U.S. Pat. No. 5,152,917 (Pieper et al.); U.S.Pat. No. 5,435,816 (Spurgeon et al.); U.S. Pat. No. 5,672,097 (Hoopmanet al.); U.S. Pat. No. 5,946,991 (Hoopman et al.); U.S. Pat. No.5,975,987 (Hoopman et al.); and U.S. Pat. No. 6,129,540 (Hoopman etal.).

Access to mold cavities can be from an opening in the top surface and/orbottom surface of the mold. In some embodiments, mold cavities canextend for the entire thickness of mold. In some embodiments, moldcavities can extend only for a portion of the thickness of the mold. Insome embodiments, the top surface is substantially parallel to bottomsurface of the mold with the mold cavities having a substantiallyuniform depth. At least one side of the mold (e.g., the side in whichthe mold cavity is formed) can remain exposed to the surroundingatmosphere during the step in which the volatile component is removed.

The mold cavities have a specified three-dimensional shape. In someembodiments, the shape of a mold cavity can be described as being atriangle, as viewed from the top, having a sloping sidewall such thatthe bottom surface of the mold cavity is slightly smaller than theopening in the top surface. A sloping sidewall may enhance grindingperformance and enable easier removal of the shaped ceramic precursorparticles from the mold. In another embodiment, the mold comprised aplurality of triangular mold cavities. Each of the plurality oftriangular mold cavities comprises an equilateral triangle.

Other mold cavity shapes can also be used such as, for example, circles,rectangles, squares, hexagons, stars, or combinations thereof, allhaving a substantially uniform depth dimension. The depth dimension isequal to the perpendicular distance from the outer edge of the moldcavity to the deepest of the mold cavity. The depth of a given moldcavity can be uniform or can vary along its length and/or width. Themold cavities of a given mold can be of the same shape or of differentshapes.

Next, the mold cavities are filled with the sol-gel composition. Anytechnique may be used such as, for example, knife roll coater or vacuumslot die coater. In some embodiments, a top surface of the mold iscoated with the sol-gel composition. Next, a scraper or leveler bar canbe used to force the sol-gel composition fully into the mold cavity ofthe mold. The remaining portion of the sol-gel composition that does notenter a mold cavity can be removed from top surface of the mold andrecycled. In some embodiments, a small portion of the sol-gelcomposition can remain on top surface and in other embodiments the topsurface is substantially free of the dispersion. The pressure applied bythe scraper or leveler bar is typically less than 100 psi (690 kPa), orless than 50 psi (340 kPa), or less than 10 psi (69 kPa). In someembodiments, no exposed surface of the sol-gel composition extendssubstantially beyond the top surface to ensure uniformity in thicknessof the resulting ceramic shaped abrasive particles.

The sol-gel composition comprises a liquid vehicle having a ceramicprecursor dissolved or dispersed therein. The sol-gel composition may bea seeded or non-seeded sol-gel composition comprising a dissolved ordispersed ceramic precursor (e.g., as nanometer-scale particles (i.e.,nanoparticles)) that can be converted into a ceramic material such as,for example, alpha alumina, silica, ceria, titania, zirconia, spinel, ora mixture thereof.

In some embodiments, the ceramic precursors are selected fromhydroxides, oxyhydroxides of aluminum, silicon, titanium, cerium, andzirconium, and water-soluble and/or reactive salts and compoundsthereof; for example, aluminum chloride hexahydrate, aluminum nitratenonahydrate, aluminum hydroxide (gibbsite), aluminum oxide monohydrate(including boehmite), aluminum isopropoxide, aluminum isobutoxide, andtetraethyl orthosilicate. In some embodiments, the metal oxide includestransition metal oxides, rare earth metal oxides, mineral oxides,ceramic oxides, or any combination thereof. Exemplary oxides includealumina, silica, titania, zirconia, yttria-stabilized zirconia, niobiumoxide, and tantalum oxide.

Many sols suitable for making ceramics are commercially available. Forexample, boehmite sols suitable for producing alpha alumina areavailable from Sasol North America Inc., Houston, Tex. Silica solssuitable for producing silica are available from Nalco Company,Naperville, Ill. Ceria sols are available from Eminess Technologies,Inc., Scottsdale, Ariz. Zirconia, silica, and alumina sols are availablefrom Nissan Chemical America Corporation, Houston Tex.

In addition to the ceramic precursor, the sol-gel composition includes aliquid vehicle that is a volatile component. Sol-gel compositions usefulin practice of the present disclosure may be free of dispersed latexparticles. In some embodiments, the volatile component comprises water.In some embodiments, the liquid vehicle comprises water in combinationwith a water-soluble or water-miscible organic solvent such as, forexample methanol, ethanol, propanol, or 2-methoxyethanol.

The sol-gel composition should comprise a sufficient amount of theliquid vehicle for the viscosity of the sol-gel composition to besufficiently low to enable filling the mold cavities and replicating themold surface, but not so much liquid vehicle as to cause subsequentremoval of the liquid vehicle from the mold cavities to be prohibitivelyexpensive. In some embodiments, the sol-gel composition comprises from 2percent to 90 percent by weight of a ceramic precursor that can beconverted into alpha alumina such as, for example, particles of aluminumoxide monohydrate, and at least 10 percent by weight, or from 50 percentto 70 percent, or 50 percent to 60 percent, by weight of water.Conversely, the sol-gel composition in some embodiments contains from 30percent to 50 percent, or 40 percent to 50 percent, by weight of theceramic precursor.

The ceramic precursor may comprise boehmite. Boehmite in suitable formcan be prepared by known techniques or can be obtained commercially.Examples of commercially available boehmite include products having thetrademarks “DISPERAL”, and “DISPAL”, both available from Sasol NorthAmerica, Inc. or “HIQ-40” available from BASF Corporation. Thesealuminum oxide monohydrates are relatively pure; i.e., they includerelatively little, if any, hydrate phases other than monohydrates, andhave a high surface area. The physical properties of the resultingceramic shaped abrasive particles will generally depend upon the type ofceramic precursor used in the sol-gel composition.

In some embodiments, the sol-gel composition is in a gel state. As usedherein, a “sol-gel” is a three-dimensional network of solids, formed bygelation of a ceramic precursor that is dissolved or dispersed in aliquid vehicle. The sol-gel composition may contain a modifying additiveor precursor of a modifying additive. The modifying additive canfunction to enhance some desirable property of the ceramic shapedabrasive particles or increase the effectiveness of the subsequentsintering step. Modifying additives or precursors of modifying additivescan be in the form of soluble salts, typically water-soluble salts. Theytypically consist of a metal-containing compound, and can be a precursorof oxides of magnesium, zinc, iron, silicon, cobalt, nickel, zirconium,hafnium, chromium, yttrium, praseodymium, samarium, ytterbium,neodymium, lanthanum, gadolinium, cerium, dysprosium, erbium, titanium,or mixtures thereof. The particular concentrations of these additivesthat can be present in the sol-gel composition can be varied based onskill in the art. Typically, the introduction of a modifying additive orprecursor of a modifying additive to the ceramic precursor will causeformation of the sol-gel composition. Ceramic precursorsolutions/dispersions can also be induced to gel by application of heatover a period of time.

The sol-gel composition can also contain a nucleating agent to enhancethe transformation of hydrated or calcined aluminum oxide to alphaalumina Nucleating agents suitable for this purpose include fineparticles of alpha alumina, alpha ferric oxide or its precursor,titanium oxides and titanates, chrome oxides, or any other material thatwill nucleate the transformation. The amount of nucleating agent, ifused, should be sufficient to effect the transformation to alpha aluminaNucleating such sol-gel compositions is disclosed in U.S. Pat. No.4,744,802 (Schwabel).

A peptizing agent can be included in the sol-gel composition to producea more stable hydrosol or colloidal sol-gel composition. Suitablepeptizing agents include, for example, monoprotic acids or acidcompounds such as acetic acid, hydrochloric acid, formic acid, andnitric acid. Multiprotic acids can also be used, but they can rapidlygel the sol-gel composition, making it difficult to handle or tointroduce additional components thereto. Some commercial sources ofboehmite contain an acid titer (such as absorbed formic or nitric acid)that will assist in forming a stable sol-gel composition.

The sol-gel composition can be formed by any suitable means, many ofwhich are well known to those of ordinary skill in the art. For example,in the case of a boehmite sol-gel, it may be prepared by simply bymixing aluminum oxide monohydrate (i.e., boehmite) with water containinga peptizing agent or by forming an aluminum oxide monohydrate slurry towhich the peptizing agent is added. Defoamers or other suitablechemicals can be added to reduce the tendency to form bubbles or entrainair while mixing. Additional chemicals such as metal oxide ceramicprecursors, wetting agents, alcohols, or coupling agents can be added ifdesired. The resultant alpha alumina abrasive particle grain may containsilica and iron oxide as disclosed in U.S. Pat. No. 5,645,619 (Ericksonet al.). Alpha alumina abrasive particles may contain zirconia asdisclosed in U.S. Pat. No. 5,551,963 (Larmie). Alternatively, alphaalumina abrasive particles can have a microstructure or additives asdisclosed in U.S. Pat. No. 6,277,161 (Castro).

The liquid vehicle comprises a volatile component (e.g., water and/ororganic solvent) and a release agent dispersed in the volatilecomponent. The release agent may be dispersed in the form of droplets orfine particles, although it may be emulsified (e.g., using one or moreemulsifiers). The sol-gel composition may contain the release agent inan amount of from 0.08 to 4.25 percent of the theoretical oxide weightof the ceramic precursor, although other amounts may also be used. Insome embodiments, the sol-gel composition contains the release agent inan amount of from 0.2 to 2.0 percent of the theoretical oxide weight ofthe ceramic precursor. In some embodiments, the sol-gel compositioncontains the release agent in an amount of from 0.42 to 0.75 percent ofthe theoretical oxide weight of the ceramic precursor.

Examples of release agents include fluorochemicals (e.g., perfluorinatedethers and polyethers, fluorinated alkanes, and combinations thereof),hydrocarbons, and silicones. The release agent may comprise an oil orcombination of oils. The release agent may be added to the remainingingredients in the sol-gel composition using a high-shear mixer orhomogenizer. Suitable high shear mixers are widely available fromcommercial sources. Once fully gelled, viscosity of the sol-gel mixtureinhibits phase bulk separation of the release agent (e.g., to form alayer on the surface of the sol-gel composition).

After filling at least some of the mold cavities with the sol-gelcomposition, the mold is placed into an oven and heated at sufficienttemperature and for sufficient time to remove a majority of the liquidvehicle, or even sufficient liquid vehicle that the dried sol-gelcomposition has sufficient resistance to flow and cohesive strength thatit can be separated from the mold and handled. Desirably, the liquidvehicle is removed at a fast evaporation rate. In some embodiments,removal of the liquid vehicle by evaporation occurs at temperaturesabove the boiling point of volatile components comprising the liquidvehicle. An upper limit to the drying temperature often depends on thematerial the mold is made from. For polypropylene molding thetemperature should be less than the melting point of the plastic.

In embodiments including an aqueous sol-gel composition of between about40 to 50 percent solids and a polypropylene mold, the dryingtemperatures can be between about 90° C. and about 165° C., or betweenabout 105° C. and about 150° C., or between about 105° C. and about 120°C.

In some embodiments, after at least partially drying the sol-gelcomposition to provide shaped ceramic precursor particles, the shapedceramic precursor particles are typically removed from the moldcavities, although if desired the mold may be consumed by combustion(e.g., during calcining) In other embodiments, the sol-gel compositioncan be removed from the mold cavities prior to drying. The sol-gelcomposition and/or shaped ceramic precursor particles can be removedfrom the mold cavities by using the following processes alone or incombination on the mold: gravity, vibration, ultrasonic vibration,vacuum, or pressurized air to remove the particles from the moldcavities.

FIGS. 2A and 2B show an exemplary shaped ceramic precursor particleaccording to the present disclosure. Referring now to FIGS. 2A and 2B,shaped ceramic precursor particle 200 is bounded by a surface 210 havinga plurality of faces 220 joined along common edges 230. Surface 210comprises voids 240 on a portion, or all of, surface 210. Voids 240comprise hollow ellipsoidal sections (e.g., as if they were scooped outwith a hemispherical ice-cream scoop). Exposed face 222 has a firstdensity of the voids 240 (i.e., the area of the void openings 445 in theexposed face 222 divided by the total area of exposed face 222). Moldface 224 has a second density of the voids 240 (i.e., the area of thevoid openings 245 in mold face 224 divided by the total area of moldface 224).

The shaped ceramic precursor particles can be further dried outside ofthe mold. If the sol-gel composition is dried to the desired level inthe mold this additional drying step is not necessary. However, in someinstances it may be economical to employ this additional drying step tominimize the time that the sol-gel composition resides in the moldcavities of the mold. Typically, the shaped abrasive precursor particleswill be dried from 10 seconds to 120 minutes, or from 1 to 10 minutes,at a temperature of from 50° C. to 160° C., or more typically at atemperature of from 120° C. to 150° C., although other conditions mayalso be used.

Without wishing to be bound by theory, it is believed that the voidsresult from oil that migrates to the surfaces as droplets, and thatpreferential migration to the exposed surface is driven by the sol-gelcomposition/air interface.

In embodiments wherein the ceramic shaped abrasive particles are formedby a method according to the present disclosure, the exposed face 222,or exposed face 322, correspond to an exposed face of the sol-gelcomposition while disposed in a mold cavity (i.e., a face not formedagainst a mold cavity wall), and mold face 224, or mold face 324,corresponds to a mold surface within the mold cavity (i.e., a faceformed against a mold cavity wall). In some embodiments, the first andsecond faces may contact each other. In other embodiments, the first andsecond faces do not contact each other (e.g., they may be spaced apartby adjoining faces, for example, as in the case of a top face and abottom face). Any or all of the faces may be planar, concave, convex, ora combination thereof. The ceramic shaped abrasive particles may have ashape selected from the group consisting of pyramids, truncatedpyramids, prisms, and combinations thereof.

At this stage, the shaped ceramic precursor particles generally containoil droplets within the interior of the particle. Upon further heatingthe oil droplets are vaporized leaving behind ellipsoidal cavitieswithin the interior of the resultant ceramic shaped abrasive particles.

Optionally, the shaped ceramic precursor particles can be calcined toprovide calcined shaped ceramic precursor particles. During calcining,essentially all volatile material is removed, and the various componentsthat were present in the ceramic precursor are transformed into metaloxides. The shaped abrasive precursor particles are generally heated toa temperature of from 400° C. to 800° C., and maintained within thistemperature range until the free water and more than 90 percent byweight of any bound volatile material are removed. In an optional step,it may be desired to introduce a modifying additive by an impregnationprocess. A water-soluble salt can be introduced by impregnation intopores of the calcined, shaped abrasive precursor particles. Then, theshaped abrasive precursor particles are calcined again. This option isfurther described in U.S. Pat. No. 5,164,348 (Wood).

The shaped ceramic precursor particles and/or calcined shaped ceramicprecursor particles can be sintered to provide the ceramic shapedabrasive particles. Prior to sintering, the calcined, shaped abrasiveprecursor particles are not completely densified, and thus lack thedesired hardness to be used as shaped abrasive particles. Sinteringtakes place by heating the calcined, shaped abrasive precursor particlesto a temperature of from about 1,000° C. to about 1,650° C., andmaintaining them within this temperature range until substantially allof the ceramic precursor material is converted into ceramic material.For example, alpha alumina monohydrate (or equivalent) may be convertedto alpha alumina and the porosity is reduced to less than 15 percent byvolume. The length of time to which the calcined, shaped abrasiveprecursor particles must be exposed to the sintering temperature toachieve this level of conversion depends upon various factors butusually from 5 seconds to 48 hours is typical.

In another embodiment, the duration for the sintering step ranges fromone minute to 90 minutes. After sintering, the resulting ceramic shapedabrasive particles can have a Vickers hardness of 10 gigapascals (GPa),16 GPa, 18 GPa, 20 GPa, or greater.

Sintering, optionally after calcining, the shaped ceramic precursorparticles results in corresponding ceramic shaped abrasive particles.After sintering, any release agent that may have been present in theshaped ceramic precursor particles has been burned off.

FIGS. 3A and 3B show an exemplary ceramic shaped abrasive particleaccording to the present disclosure. Referring now to FIGS. 3A and 3B,ceramic shaped abrasive particle 300 is bounded by a surface 310 havinga plurality of faces 320 joined along common edges 330. Surface 310comprises voids 340 on a portion, or all of, surface 310. Voids 340comprise hollow ellipsoidal sections (e.g., as if they were scooped outwith a hemispherical ice-cream scoop). Exposed face 322 has a firstdensity of the voids 340 (i.e., the area of the void openings 345 in theexposed face 322 divided by the total area of exposed face 322). Moldface 324 has a second density of the voids 340 (i.e., the area of thevoid openings 345 in mold face 324 divided by the total area of moldface 324).

Other steps can be used to modify the described process such as, forexample, rapidly heating the material from the calcining temperature tothe sintering temperature, centrifuging the sol-gel composition toremove sludge or other waste. Moreover, the process can be modified bycombining two or more of the process steps if desired. Conventionalprocess steps that can be used to modify the process of this disclosureare more fully described in U.S. Pat. No. 4,314,827 (Leitheiser).Additionally, the ceramic shaped abrasive particles can have grooves onone of the faces as described in U.S. Patent Appln. Publ. No.2010/0146867 A1 (Boden et al.). The grooves are formed by a plurality ofridges in the bottom surface of the mold cavities, and may make iteasier to remove the shaped abrasive precursor particles from the mold.More information concerning methods to make ceramic shaped abrasiveparticles is disclosed in U. S. Patent Appl. Publ. No. 2009/0165394 A1(Culler et al.).

In some embodiments, the ceramic shaped abrasive particles comprisealpha alumina. In those embodiments, and others, the ceramic shapedabrasive particles may have a true density of at least 3.8, at least3.85, or even at least 3.9 grams per cubic centimeter.

In embodiments wherein the ceramic shaped abrasive particles are formedby a method according to the present disclosure, the exposed face 222,or exposed face 322, correspond to an exposed face of the sol-gelcomposition while disposed in a mold cavity (i.e., a face not formedagainst a mold cavity wall), and mold face 224, or mold face 324,corresponds to a mold surface within the mold cavity (i.e., a faceformed against a mold cavity wall). In some embodiments, the first andsecond faces may contact each other. In other embodiments, the first andsecond faces do not contact each other (e.g., they may be spaced apartby adjoining faces, for example, as in the case of a top face and abottom face). Any or all of the faces may be planar, concave, convex, ora combination thereof. The ceramic shaped abrasive particles may have ashape selected from the group consisting of pyramids, truncatedpyramids, prisms, and combinations thereof.

In some embodiments, the voids of the ceramic shaped abrasive precursorparticles and/or the ceramic shaped abrasive particles have an averageFeret diameter in a range of from about 1.2 microns to about 2.0microns, or from about 1.5 microns to about 1.7 microns.

Ceramic shaped abrasive particles according to the present disclosurecan be incorporated into an abrasive article, or used in loose form.Abrasive particles are generally graded to a given particle sizedistribution before use. Such distributions typically have a range ofparticle sizes, from coarse particles to fine particles. In the abrasiveart this range is sometimes referred to as a “coarse”, “control”, and“fine” fractions. Abrasive particles graded according to abrasiveindustry accepted grading standards specify the particle sizedistribution for each nominal grade within numerical limits. Suchindustry accepted grading standards (i.e., abrasive industry specifiednominal grade) include those known as the American National StandardsInstitute, Inc. (ANSI) standards, Federation of European Producers ofAbrasive Products (FEPA) standards, and Japanese Industrial Standard(JIS) standards.

ANSI grade designations (i.e., specified nominal grades) include: ANSI4, ANSI 6, ANSI 8, ANSI 16, ANSI 24, ANSI 36, ANSI 40, ANSI 50, ANSI 60,ANSI 80, ANSI 100, ANSI 120, ANSI 150, ANSI 180, ANSI 220, ANSI 240,ANSI 280, ANSI 320, ANSI 360, ANSI 400, and ANSI 600. FEPA gradedesignations include P8, P12, P16, P24, P36, P40, P50, P60, P80, P100,P120, P150, P180, P220, P320, P400, P500, P600, P800, P1000, and P1200.JIS grade designations include JIS8, JIS12, JIS16, JIS24, JIS36, JIS46,JIS54, JIS60, JIS80, JIS100, JIS150, JIS180, JIS220, JIS240, JIS280,JIS320, JIS360, JIS400, JIS600, JIS800, JIS1000, JIS1500, JIS2500,JIS4000, JIS6000, JIS8000, and JIS10,000.

Alternatively, the ceramic shaped abrasive particles can be graded to anominal screened grade using U.S.A. Standard Test Sieves conforming toASTM E-11 “Standard Specification for Wire Cloth and Sieves for TestingPurposes.” ASTM E-11 proscribes the requirements for the design andconstruction of testing sieves using a medium of woven wire clothmounted in a frame for the classification of materials according to adesignated particle size. A typical designation may be represented as−18+20 meaning that the ceramic shaped abrasive particles pass through asieve meeting ASTM E-11 specifications for the number 18 sieve and areretained on a sieve meeting ASTM E-11 specifications for the number 20sieve. In some embodiments, the ceramic shaped abrasive particles have aparticle size such that most of the particles pass through an 18 meshtest sieve and can be retained on a 20, 25, 30, 35, 40, 45, or 50 meshtest sieve. In various embodiments, the ceramic shaped abrasiveparticles can have a nominal screened grade comprising: −18+20, −20+25,−25+30, −30+35, −35+40, −40+45, −45+50, −50+60, −60+70, −70+80, −80+100,−100+120, −120+140, −140+170, −170+200, −200+230, −230+270, −270+325,−325+400, −400+450, −450+500, or −500+635. In some embodiments, theceramic shaped abrasive particles have a particle size less than 25millimeters, less than 15 millimeters, or less than 5 millimeters.

If desired, ceramic shaped abrasive particles having an abrasivesindustry specified nominal grade or a nominal screened grade can bemixed with other known abrasive or non-abrasive particles. In someembodiments, at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65,70, 75, 80, 85, 90, 95, or even 100 percent by weight of the pluralityof abrasive particles having an abrasives industry specified nominalgrade or a nominal screened grade are ceramic shaped abrasive particlesaccording to the present disclosure, based on the total weight of theplurality of abrasive particles.

Particles suitable for mixing with the ceramic shaped abrasive particlesinclude conventional abrasive grains, diluent grains, or erodibleagglomerates, such as those described in U.S. Pat. No. 4,799,939(Markhoff-Matheny et al.) and U.S. Pat. No. 5,078,753 (Broberg et al.).Representative examples of conventional abrasive grains include fusedaluminum oxide, silicon carbide, garnet, fused alumina zirconia, cubicboron nitride, diamond, and the like. Representative examples of diluentgrains include marble, gypsum, and glass. Blends of differently shapedceramic shaped abrasive particles can be used in the articles of thisinvention.

The ceramic shaped abrasive particles may also have a surface coating.Surface coatings are known to improve the adhesion between abrasivegrains and the binder in abrasive articles or can be used to aid inelectrostatic deposition of the ceramic shaped abrasive particles. Suchsurface coatings are described in U.S. Pat. No. 5,213,591 (Celikkaya etal.); U.S. Pat. No. 5,011,508 (Wald et al.); U.S. Pat. No. 1,910,444(Nicholson); U.S. Pat. No. 3,041,156 (Rowse et al.); U.S. Pat. No.5,009,675 (Kunz et al.); U.S. Pat. No. 5,085,671 (Martin et al.); U.S.Pat. No. 4,997,461 (Markhoff-Matheny et al.); and U.S. Pat. No.5,042,991 (Kunz). Additionally, the surface coating may prevent theshaped abrasive particle from capping. Capping is the term to describethe phenomenon where metal particles from the workpiece being abradedbecome welded to the tops of the shaped abrasive particles. Surfacecoatings to perform the above functions are known to those of skill inthe art.

Objects and advantages of this disclosure are further illustrated by thefollowing non-limiting examples, but the particular materials andamounts thereof recited in these examples, as well as other conditionsand details, should not be construed to unduly limit this disclosure.

EXAMPLES

Unless otherwise noted, all parts, percentages, ratios, etc. in theExamples and the rest of the specification are by weight.

Example 1

An alumina sol was prepared by combining 2316 grams deionized water and66 grams of nitric acid in a high-shear mixer (Scott Turbon Mixer,Adelanto, Calif.) operating at 1601 RPM. 1600 grams of aluminum oxidemonohydrate (available as DISPERAL from Sasol North America, Houston,Tex.) was added over one minute After 5 minutes, an additional 6 gramsof nitric acid were added, after seven minutes of mixing 12 grams ofpeanut oil (available as PEANUT OIL, N.F. from Alnor Oil Company, ValleyStream, N.Y.) (0.88 percent of theoretical oxide weight of boehmite) wasadded to the mix and incorporated for 2 minutes. The batch size was 4000grams. The resultant composition was allowed to gel and age for 24 hoursbefore use thereby providing a sol-gel composition.

The sol-gel composition was forced into cavities of a microreplicatedmold using a 5-inch (13-cm) wide stainless steel putty knife. The moldwas a 9 in×13 in (23 cm×33 cm) piece of polypropylene havingtriangular-shaped mold cavities (110 mils (2.8 mm) each side×28 mils(0.7 mm) deep). The draft angle between the sidewall mold face andbottom mold face was 98 degrees. The mold was manufactured to have 50percent of the mold cavities with 8 parallel ridges rising from thebottom surfaces of the mold cavities that intersected with one side ofthe triangle at a 90 degree angle, and the remaining mold cavities had asmooth bottom mold cavity surface. The parallel ridges were spaced every0.277 mm, and the cross-section of the ridges was a triangle shapehaving a height of 0.0127 mm and a 45 degree angle between the sides ofeach ridge at the tip. The excess sol-gel composition was carefullyremoved from the molding with the putty knife. The coated molding wasthen placed in an air convection oven at 45° C. for 1.5 hours to removewater and dry the sol-gel composition to shaped particles. The particleswere removed from the molding with the aid of an ultrasonic horn. Theshaped abrasive precursor particles with 0.75 percent peanut oil werecalcined at approximately 650° C. (15 minutes) and then saturated with amixed nitrate solution of the following concentration (reported asoxides): 1.0% MgO, 1.2% Y₂O₃, 4.0% La₂O₃ and 0.05% CoO. The excessnitrate solution was removed and the saturated shaped abrasive precursorparticles were allowed to dry after which the particles were againcalcined at 650° C. (15 minutes) and sintered at approximately 1400° C.(5 minutes). Both the calcining and sintering was performed using rotarytube kilns. The resulting shaped particles were evaluated for bulkdensity and true density. Bulk Density was measured according to ANSIB74.4-1992 “Procedure for Bulk Density of Abrasive Grains.” The TrueDensity was measured using a Micromeritics ACCUPYC 1330 HELIUMPYCNOMETER (Micromeritics Instrument Corporation, Norcross, Ga.).

Comparative Example A

Comparative Example A was made identically to that of Example 7, withthe exception that no peanut oil was added. Substantially all of theparticles fractured while drying in the mold cavities, but releasedsuccessfully from the mold.

Examples 2-11

Examples 2-12 were prepared as in Example 1, with the exception thatvarying amounts of peanut oil were incorporated as shown in Table 1.

Comparative Example B

A boehmite sol-gel was made using the following recipe: aluminum oxidemonohydrate powder (1600 parts) having the trade designation “DISPERAL”was dispersed by high shear mixing a solution containing water (2400parts) and 70 percent aqueous nitric acid (72 parts) for 11 minutes. Theresulting sol-gel was aged for at least one hour before coating. Thesol-gel was forced into a mold having triangular shaped mold cavities of28 mils (0.71 mm) depth and 110 mils (2.79 mm) on each side. The draftangle between the sidewall and bottom of the mold cavity was 98 degrees.The mold was manufactured to have 50 percent of the mold cavities with 8parallel ridges rising from the bottom surfaces of the mold cavitiesthat intersected with one side of the triangle at a 90 degree angle andthe remaining mold cavities had a smooth bottom surface. The parallelridges were spaced every 0.277 mm and the cross section of the ridgeswas a triangle shape having a height of 0.0127 mm and a 45 degree anglebetween the sides of each ridge at the tip as described in U.S. PatentAppln. Publ. No. 2010/0146867 A1 (Boden et al.).

The sol-gel was forced into the mold cavities with a putty knife so thatthe openings of the molding were completely filled. A mold releaseagent, 0.2 percent peanut oil in methanol was used to coat the moldingwith about 0.5 mg/in² (0.08 mg/cm²) of peanut oil applied to themolding. The excess methanol was removed by placing sheets of themolding in an air convection oven for 5 minutes at 45° C. The sol-gelcoated molding was placed in an air convection oven at 45° C. for atleast 45 minutes to dry. The precursor shaped abrasive particles wereremoved from the molding by passing it over an ultrasonic horn. Theprecursor shaped abrasive particles were calcined at approximately 650°C., and then saturated with a mixed nitrate solution of the followingconcentration (reported as oxides): 1.8 percent each of MgO, Y₂O₃,Nd₂O₃, and La₂O₃. The excess nitrate solution was removed and thesaturated precursor shaped abrasive particles with openings were allowedto dry after which the particles were again calcined at 650° C. andsintered at approximately 1400° C. Both the calcining and sintering wasperformed using rotary tube kilns.

Composition and/or density of Examples 1-11 and Comparative Examples Aand B are reported in Table 1 (below).

TABLE 1 PEANUT OIL, PEANUT OIL, as calculated as a percent of a percentof the weight of theoretical oxide BULK DENSITY, TRUE DENSITY, aluminumoxide weight of aluminum grams per cubic grams per cubic EXAMPLEmonohydrate oxide monohydrate centimeter centimeter Comparative 0 0 1.53.965 Example A Comparative 0 0, oil applied 1.82 3.9635 Example B tomold 2 0.1 0.1 1.71 3.9662 3 0.2 0.2 1.69 3.9551 4 0.3 0.4 1.66 3.9544 50.4 0.5 1.73 3.9505 6 0.5 0.6 1.77 3.9445 7 0.65 0.76 1.77 3.9354 1 0.750.88 1.83 3.9292 8 0.85 1.0 1.74 3.9074 9 1.0 1.2 1.77 3.8883 10 1.5 1.81.81 3.8745 11 2.0 2.4 1.81 3.8161

For Examples 1 to 11, the shaped abrasive particle precursors readilyreleased from their respective mold cavities without the need forrelease agents separately applied to the molding. As is apparent fromTable 1, the introduction of increasing amounts of peanut oil into thesol-gel composition resulted in an increase in bulk density (due, atleast in part, to an increase in particle shrinkage at firing) and adecrease in true density (due to the introduction of porosity).

X-Ray diffraction confirmed that the ceramic shaped abrasive particlesprepared in Examples 2-11 were primarily corundum with a detectableamount of magnesium lanthanum aluminate. This is the typical andexpected fired chemistry for this material.

Example 12

Example 12 was prepared as in Example 1, with the exception that peanutoil was included in an amount of 2.75 percent of the weight of aluminumoxide monohydrate (3.24 percent of theoretical oxide weight). FIGS. 4Aand 4B respectively show the top (exposed) surface and the bottom (mold)surface of a resultant ceramic shaped abrasive particle. Thesephotomicrographs show the non-uniform distribution of voids on the twofaces, with FIG. 4A showing at least 10 times the number of voidscompared with FIG. 4B.

Example 13

The exposed face (corresponding to a mold cavity outer opening) and abottom mold face (opposite the exposed outer face) of ten ceramic shapedabrasive particles (i.e., fired) prepared according to Example 7 (i.e.,peanut oil was present in an amount of 0.65 percent of the weight ofaluminum oxide monohydrate) were independently imaged using a JEOL 7600Ffield emission scanning electron microscope (from JEOL Ltd., Tokyo,Japan) at 2,000× using backscattered electrons. Because of therelatively high magnification, a random area was selected on each of theparticles. The images were subsequently analyzed using ImageJ imageanalysis software. Data was obtained by manually measuring the area ofindividual exposed voids and combining these individual pore areameasurements to obtain the total area of voids per image, and thendividing this value by the total field of view area to ultimately obtainthe “area percentage covered with porosity” for each of the ten exposedfaces and ten mold faces. The percent of the surface area of each facethat was occupied by the voids was as follows: exposed face-mean=0.72percent, standard deviation=0.50 percent; and mold face-mean=0.16percent, standard deviation=0.14 percent.

Example 14

The procedure was the same as that of Example 7, except that coconut oilwas substituted for peanut oil, and the coconut oil was heated in anoven at 45° C. until it was liquid prior to combining with the remainingcomponents.

Example 15

A metal screen was used in this example. The metal screen was 22 mils(0.56 mm) thick, and had equilateral triangular openings, 0.110 inch(2.8 mm) on each side. Sol-gel composition prepared as in Example 1 wasapplied to the metal screen using a putty knife, thereby filling theopenings in the screen. The screen was removed immediately and thesample was dried at 45° C. for 15 minutes.

Example 16

Example 15 was repeated, except: the metal screen was held verticalwhile sol-gel was applied using a plastic squeegee; excess sol-gel wasskived away on both sides of screen simultaneously; the sol-gel coatedmetal screen was dried at 45° C. for 15 minutes; and particles fell fromscreen into a collection pan during drying.

Example 17

The exposed face (corresponding to a mold cavity outer opening) and thebottom mold face (opposite the exposed outer face) of ten ceramic shapedabrasive precursor (i.e., unfired) particles were independently imagedusing a JEOL 7600F field emission scanning electron microscope at 2,000×using backscattered electrons. The particles were prepared according toExample 1, except that the particles were unfired and the level ofpeanut oil was 2.5 percent of the weight of aluminum oxide monohydrate(2.9 percent of theoretical oxide weight). Because of the relativelyhigh magnification, a random area was selected on each of the particles.The images were subsequently analyzed using ImageJ image analysissoftware. Data was obtained by manually measuring the area of individualexposed voids and combining these individual pore area measurements toobtain the total area of voids per image, and then dividing this valueby the total field of view area to ultimately obtain the “areapercentage covered with porosity” for each of the ten exposed faces andten mold faces. The percent of the surface area of each face that wasoccupied by the voids was as follows: exposed face-mean=6.5 percent,standard deviation=1.7 percent; and mold face-mean=0.8 percent, standarddeviation=0.4 percent.

Example 18

The exposed face (corresponding to a mold cavity outer opening) and thebottom mold face (opposite the exposed outer face) of ten ceramic shapedabrasive (i.e., fired) particles were independently imaged using a JEOL7600F field emission scanning electron microscope at 2,000× usingbackscattered electrons. The particles were prepared according toExample 1, except that the level of peanut oil was 2.5 percent of theweight of aluminum oxide monohydrate (2.9 percent of theoretical oxideweight). Because of the relatively high magnification, a random area wasselected on each of the particles. The images were subsequently analyzedusing ImageJ image analysis software. Data was obtained by manuallymeasuring the area of individual exposed voids and combining theseindividual pore area measurements to obtain the total area of voids perimage, and then dividing this value by the total field of view area toultimately obtain the “area percentage covered with porosity” for eachof the ten exposed faces and ten mold faces. The percent of the surfacearea of each face that was occupied by the voids was as follows: exposedface-mean=6.04 percent, standard deviation=2.21 percent; and moldface-mean=0.24 percent, standard deviation=0.18 percent. The mean Feretdiameter of voids on the exposed face was 1.57 microns, standarddeviation=0.79 micron, and on the mold face it was 1.64 microns,standard deviation=0.72 micron.

Example 19

The exposed face (corresponding to a mold cavity outer opening) and thebottom mold face (opposite the exposed outer face) of ten ceramic shapedabrasive particles (fired) were independently imaged using a JEOL 7600Ffield emission scanning electron microscope at 2,000× usingbackscattered electrons. The particles were prepared according toExample 2 (i.e., peanut oil was present in an amount of 0.1 percent ofthe weight of aluminum oxide monohydrate). Because of the relativelyhigh magnification, a random area was selected on each of the particles.The images were subsequently analyzed using ImageJ image analysissoftware. Data was obtained by manually measuring the area of individualexposed voids and combining these individual pore area measurements toobtain the total area of voids per image, and then dividing this valueby the total field of view area to ultimately obtain the “areapercentage covered with porosity” for each of the ten exposed faces andten mold faces. The percent of the surface area of each face that wasoccupied by the voids was as follows: exposed face-mean=0.11 percent,standard deviation=0.08 percent; and mold face-mean=0.04 percent,standard deviation=0.04 percent.

Select Embodiments Of The Present Disclosure

In a first embodiment, the present disclosure provides a method ofmaking shaped ceramic precursor particles, the method comprising:

providing a mold having a plurality of mold cavities, wherein each moldcavity is bounded by a plurality of faces joined along common edges;

filling at least some of the mold cavities with a sol-gel composition,the sol-gel composition comprising a liquid vehicle and a ceramicprecursor, the liquid vehicle comprising a volatile component and arelease agent dispersed throughout the volatile component;

removing at least a portion of the volatile component from the sol-gelcomposition while the sol-gel composition resides in the mold cavitiesthereby providing the shaped ceramic precursor particles.

In a second embodiment, the present disclosure provides a method ofmaking shaped ceramic precursor particles according to the firstembodiment, further comprising separating the shaped ceramic precursorparticles from the mold.

In a third embodiment, the present disclosure provides a method ofmaking ceramic shaped abrasive particles, the method comprising:

making shaped ceramic precursor particles according to the method of thefirst or second embodiment; and

sintering at least a portion of the shaped ceramic precursor particlesto provide the ceramic shaped abrasive particles.

In a fourth embodiment, the present disclosure provides a method ofmaking ceramic shaped abrasive particles, the method comprising:

making shaped ceramic precursor particles according to the method of anyone of the first to third embodiments;

calcining at least a portion of the shaped ceramic precursor particlesof claim 1 to provide calcined shaped ceramic precursor particles; and

sintering at least a portion of the calcined shaped ceramic precursorparticles to provide the ceramic shaped abrasive particles.

In a fifth embodiment, the present disclosure provides a methodaccording to the third or fourth embodiment, wherein the ceramic shapedabrasive particles comprise alpha alumina

In a sixth embodiment, the present disclosure provides a methodaccording to any one of the third to fifth embodiments, wherein theceramic shaped abrasive particles have an abrasives industry specifiednominal grade.

In a seventh embodiment, the present disclosure provides a methodaccording to any one of the third to sixth embodiments, wherein theceramic shaped abrasive particles have a particle size of less than 5millimeters.

In an eighth embodiment, the present disclosure provides a methodaccording to any one of the third to the seventh embodiments, whereinthe ceramic shaped abrasive particles have a true density of at least3.8 grams per cubic centimeter.

In a ninth embodiment, the present disclosure provides a methodaccording to any one of the first to eighth embodiments, wherein therelease agent comprises an oil.

In a tenth embodiment, the present disclosure provides a methodaccording to any one of the first to ninth embodiments, wherein therelease agent is included in the sol-gel composition in an amount offrom 0.08 to 4.25 percent of the theoretical oxide weight of the ceramicprecursor.

In an eleventh embodiment, the present disclosure provides a methodaccording to any one of the first to tenth embodiments, wherein theceramic precursor comprises an alpha alumina precursor.

In a twelfth embodiment, the present disclosure provides a sol-gelcomposition comprising a liquid vehicle and a ceramic precursor, theliquid vehicle comprising a volatile component and oil dispersedthroughout the volatile component, wherein the sol-gel compositioncomprises a sol-gel.

In a thirteenth embodiment, the present disclosure provides a sol-gelcomposition according to the twelfth embodiment, wherein the releaseagent comprises an oil.

In a fourteenth embodiment, the present disclosure provides a sol-gelcomposition according to the twelfth or thirteenth embodiment, whereinthe release agent is included in the sol-gel composition in an amount offrom 0.08 to 4.25 percent of the theoretical oxide weight of the ceramicprecursor.

In a fifteenth embodiment, the present disclosure provides a sol-gelcomposition according to any one of the twelfth to fourteenthembodiments, wherein the ceramic precursor comprises an alpha aluminaprecursor.

In a sixteenth embodiment, the present disclosure provides shapedceramic precursor particles, wherein each shaped ceramic precursorparticle comprises a ceramic precursor and is bounded by a surfacehaving a plurality of faces joined along common edges, wherein thesurface has voids on at least a portion thereof, wherein the voids areshaped as hollow ellipsoidal sections, wherein the plurality of facescomprises:

-   -   an exposed face having a portion of the voids thereon, wherein        the exposed face has a first density of the voids; and    -   a mold face that is smaller in area than the exposed face,        wherein the mold face has a portion of the voids thereon,        wherein the mold face has a second density of the voids, and

wherein the first density of the voids is greater than the seconddensity of the voids.

In a seventeenth embodiment, the present disclosure provides ceramicshaped abrasive particles according to the sixteenth embodiment, whereinthe exposed face is opposite the mold face.

In an eighteenth embodiment, the present disclosure provides shapedceramic precursor particles, wherein each shaped ceramic precursorparticle comprises a ceramic precursor and is bounded by a surfacehaving a plurality of faces joined along common edges, wherein thesurface has voids on at least a portion thereof, wherein the voids areshaped as hollow ellipsoidal sections, wherein the plurality of facescomprises:

-   -   an exposed face having a portion of the voids thereon, wherein        the exposed face has a first density of the voids; and    -   a mold face, wherein the mold face has a portion of the voids        thereon, wherein the mold face has a second density of the        voids, and wherein the first density of the voids is greater        than the second density of the voids.

In a nineteenth embodiment, the present disclosure provides ceramicshaped abrasive particles according to the eighteenth embodiment,wherein the exposed face is opposite the mold face.

In a twentieth embodiment, the present disclosure provides ceramicshaped abrasive particles, wherein each ceramic shaped abrasive particlecomprises a ceramic material and is bounded by a surface having aplurality of faces joined along common edges, wherein the surface hasvoids on at least a portion thereof, wherein the voids are shaped ashollow ellipsoidal sections, wherein the plurality of faces comprises:

-   -   an exposed face having a portion of the voids thereon, wherein        the exposed face has a first density of the voids; and    -   a mold face that is smaller in area than the exposed face,        wherein the mold face has a portion of the voids thereon,        wherein the mold face has a second density of the voids, and        wherein the first density of the voids is greater than the        second density of the voids.

In a twenty-first embodiment, the present disclosure provides ceramicshaped abrasive particles according to the twentieth embodiment, whereinthe exposed face is opposite the mold face.

In a twenty-second embodiment, the present disclosure provides Ceramicshaped abrasive particles, wherein each ceramic shaped abrasive particlecomprises a ceramic material and is bounded by a surface having aplurality of faces joined along common edges, wherein the surface hasvoids on at least a portion thereof, wherein the voids are shaped ashollow ellipsoidal sections, wherein the plurality of faces comprises:

-   -   an exposed face having a portion of the voids thereon, wherein        the exposed face has a first density of the voids; and    -   a mold face, wherein the mold face has a portion of the voids        thereon, wherein the mold face has a second density of the        voids, and wherein the first density of the voids is greater        than the second density of the voids.

In a twenty-third embodiment, the present disclosure provides shapedceramic precursor particles according to the twenty-second embodiment,wherein the exposed face is opposite the mold face.

In a twenty-fourth embodiment, the present disclosure provides ceramicshaped abrasive particles according to any one of the twentieth totwenty-third embodiments, wherein the ceramic shaped abrasive particleshave an abrasives industry specified nominal grade.

In a twenty-fifth embodiment, the present disclosure provides ceramicshaped abrasive particles according to any one of the twentieth totwenty-fourth embodiments, wherein the ceramic shaped abrasive particleshave a particle size less than 5 millimeters.

In a twenty-sixth embodiment, the present disclosure provides ceramicshaped abrasive particles according to any one of the twentieth totwenty-fifth embodiments, wherein the ceramic shaped abrasive particlescomprise alpha alumina.

In a twenty-seventh embodiment, the present disclosure provides ceramicshaped abrasive particles according to any one of the twentieth totwenty-sixth embodiments, wherein the ceramic shaped abrasive particleshave a true density of at least 3.8 grams per cubic centimeter.

All patents and patents and publications cited hereinabove areincorporated herein by reference, unless specifically excluded. Variousmodifications and alterations of this disclosure may be made by thoseskilled in the art without departing from the scope and spirit of thisdisclosure, and it should be understood that this disclosure is not tobe unduly limited to the illustrative embodiments set forth herein.

What is claimed is:
 1. A method of making shaped ceramic precursorparticles, the method comprising: providing a mold having a plurality ofmold cavities, wherein each mold cavity is bounded by a plurality offaces joined along common edges; filling at least some of the moldcavities with a sol-gel composition, the sol-gel composition comprisinga liquid vehicle and a ceramic precursor comprising an alpha aluminaprecursor, the liquid vehicle comprising a volatile component and arelease agent dispersed throughout the volatile component, wherein therelease agent comprises an oil; and removing at least a portion of thevolatile component from the sol-gel composition while the sol-gelcomposition resides in the mold cavities thereby providing the shapedceramic precursor particles.
 2. The method of claim 1, furthercomprising separating the shaped ceramic precursor particles from themold.
 3. A method of making ceramic shaped abrasive particles, themethod comprising: making shaped ceramic precursor particles accordingto the method of claim 1; and sintering at least a portion of the shapedceramic precursor particles to provide the ceramic shaped abrasiveparticles.
 4. A method of making ceramic shaped abrasive particles, themethod comprising: making shaped ceramic precursor particles accordingto the method of claim 1; calcining at least a portion of the shapedceramic precursor particles to provide calcined shaped ceramic precursorparticles; and sintering at least a portion of the calcined shapedceramic precursor particles to provide the ceramic shaped abrasiveparticles.
 5. The method of claim 4, wherein the ceramic shaped abrasiveparticles have an abrasives industry specified nominal grade.
 6. Themethod of claim 4, wherein the release agent is included in the sol-gelcomposition in an amount of from 0.08 to 4.25 percent of the theoreticaloxide weight of the ceramic precursor.